Series Resonant Converter with Series-Parallel Transformers for High Input Voltage Applications

C-H Chien1,B-R Lin2,and Y-H Wang1

1

Institute of Microelectronics, Department of Electrical Engineering, National Cheng-Kung University, Tainan 701, Taiwan 2 Department of Electrical Engineering, National Yunlin University of Science and Technology, Yunlin 640, Taiwan

Outline
Introduction Circuit configuration Experimental results Conclusion

Introductio n
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Whats for in this study?

For 3-phase 380V (or 480V) AC/DC converters

the DC bus voltage > 500V (or 650V)

select suitable power MOSFETs difficult

3 level neutral-point clamp converter overcome these drawbacks

more power switches more circuit components high cost complicated control schemes split capacitors and clamp diodes

the Vstress of MOSFETs

Whats new in this study?

A novel DC/DC converter (24V/40A, 960W)

2 circuit modules for high voltage application 2 capacitors and 2 half-bridge

series in high Voltage

clamp the Vstress of MOSFET

Vstress = input V

interleaved switching signal phase-shift switching T 90

reduce ripple current (input and output) share the load current reduce the size of magnetic core

Why is the topology ?

A series resonant tank

high conversion efficiency high power density 2 series Transformers

balance the 2 winding current switching loss

all semiconductors soft switching

(ZVS & ZCS) 480V~600V all load 6

wide input voltage and load

2 windings in parallel

Circuit configuration
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Circuit configuration and key waveforms

Circuit configuration

8 Key waveforms

Different modes during 1 period

Mode 1

Mode 3

Mode 5

Mode 2

Mode 4

9 Mode 6

Mode 1 ( t0t t1 )

S1 off , S2 off

VLm1=nVo= VLm2 Cs1, Cs2, and Lr1 resonant iLr1

Cs2 => from 0 V Vin/2 charge Cs1 => from Vin/2 0 V discharge n
iLm1(t ) = iLm1(t0 ) + nV0 (t t0 ) p , n= Lm ns nV (t t0 ) iLm 2(t ) = iLm 2(t0 ) + 0 , Lm1 = Lm 2 = Lm Lm

iLm1 iLm2 iD1

iD1 (t ) = n(iLr1 (t ) iLm1 (t ))

iD 3 (t ) = n(iLr1 (t ) iLm 2 (t ))

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Mode 2 ( t1t t2 )

S2 off , S1 ZVS on

iLm1= iLm2= iLr1 mode end VLm1=nVo= VLm2 Cr1 and Lr1 resonant

applied voltage = (Vin/2 2nV0)

iLm1 ,iLm2
linearly 1 = nV /L Lr1 slope m = r = ,0 Z r

iLr1

VCr1 (t ) = Vin / 2 2nVo [Vin / 2 nVo Vcr1 (t1 )] cos r (t t1 ) + iLr1 (t1 ) Z r sin r (t t1 )

C r1 Lr1Cr1 V / 2 2nVo vcr1 (t1 ) iLr1(t ) = in sin r (t t1 ) + iLr1 (t1 ) cos r (t t1 ) Zr

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Mode 3 ( t2t t3 )

S2 off , S1 on off

iLm1= iLm2= iLr1 mode start S1 off mode end iD1=iD2=iD3=iD4=0 Cr1, Lr1, Lm1, and Lm2 resonant
p =
1 ( Lr1 + Lm1 + Lm 2 )Cr1 , Zr = ( Lr1 + Lm1 + Lm 2 ) C r1

Vin / 2 vcr1 (t 2 ) iLr1 iLr 1(t ) = sin Zp

(t t 2 ) + iLr1 (t2 ) cos p (t t2 )

V V Vcr1 VCr1 (t ) = in [ in Vcr1 (t 2 )] cos p (t t2 ) + iLr1 (t 2 ) Z p sin p (t 12 t2 ) 2 2

Mode 4 ( t3t t4 )

S2 off , S1 off

VLm1=-nVo= VLm2 Cs1, Cs2, and Lr1 resonant iLr1

iLm1 ,iLm2

Cs1 => from 0 V Vin/2 charge Cs2 => from Vin/2 0 V discharge linearly slope = -nV iL 0/L (t3m )
Vcs1 (t )
r1

Vcs1 Vcs2 iD2

2C s V (t ) Vin iLr 1 (t3 ) (t t ) cs 2 3 2 2C s

(t t3 ), C s = C s1 = C s 2

iD 2 (t ) = n(iLm1 (t ) iLr1 (t ))

iD 4 (t ) = n(iLm1 (t ) iLr 2 (t ))

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Mode 5 ( t4t t5 )

S1 off , S2 ZVS on

iLm1= iLm2= iLr1 mode end VLm1=-nVo= VLm2 Cr1 and Lr1 resonant

applied voltage = 2nV0

iLm1 ,iLm2
linearly 1 slope = -nV, = r 0/LZ m r =

Lr1Cr1

iLr1

iLr1(t ) =

VCr1 (t ) = 2nVo [2nVo Vcr1 (t4 )] cos r (t t 4 ) + iLr1 (t 4 ) Z r sin r14 (t t 4 )

2nVo vcr1 (t 4 ) sin r (t t 4 ) + iLr1 (t 4 ) cos r (t t 4 ) Zr

Lr1 C r1

Mode 6 ( t5t t0 )

S1 off , S2 on off

iLm1= iLm2= iLr1 mode start S2 off mode end iD1=iD2=iD3=iD4=0 Cr1, Lr1, Lm1, and Lm2 resonant
p

1 ( Lr1 + Lm1 + Lm 2 )Cr1

, Zr =

( Lr1 + Lm1 + Lm 2 ) Cr1

vcr1 (t5 ) iLr1 iLr 1(t ) = sin Zp

(t t5 ) + iLr1 (t5 ) cos p (t t5 )

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Vcr1 VCr 1 (t ) = Vcr1 (t5 ) cos p (t t5 ) + iLr 1 (t5 ) Z p sin p (t t5 )

Key circuit parameters of the prototype circuit

Input voltage Vin Input nominal Vin,norm Output voltage Vo and current Io Series resonant frequency fr Switches S1~S4 Diodes D1~D8 Turns ratio of T1~T4 Resonant inductances Lr1~ Lr2 Resonant capacitances Cin1~ Cin2 Output capacitances Co

480V ~ 600V 530V 24V / 40A 100kHz IRFP460 MBR3060PT np:ns1:ns2=20:6:6 21 H 330 F/400V

Magnetizing inductances Lm1~ Lm4 82 H

16 2200 F/50V

Experimental results
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The interleaved signals of switches

Experimental waveforms of gate voltages

S1~S4 at full load Vin=530V

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The ZVS of switches under input 530V

Experimental gate V, drain V and drain I of switch S1

Vin 530V load 25%

Experimental gate V, drain V and drain I of switch S1

Vin 530V load 100%

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The ZCS of rectifier diodes under input 530V

Measured waveforms of gate voltages

vS1,gs and vS3,gs

Output currents of each center tapped rectifier

at full load nominal input voltage

Vin=530V
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turn off

Switching Frequency VS. Output Power

Measured switching frequencies

at different input voltages at different load

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Conclusio n
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Conclusion

A resonant converter

with the series half-bridge legs for high DC bus voltage application share the load power

The voltage stress of each switch=0.5Vin

Two circuit modules balance 2 winding current

For each module

share the load current

series-connected in primary side parallel-connected in secondary side power MOSFETs turn on ZVS rectifier diodes turn off ZCS
switching loss
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Thanks for your attention!

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